Pile fabric



p 9 195% R. R. CONE EE'AL 252L831 FILE FABRIC Filed April 28, 1947 2 Sheets-Sheet. 1

FIEGE- Z6 I mm w ,50

Sept. 12, 1950 R. R. CONE EAL PILE FABRIC 2 Sheets-Sheet 2 Filed April 28, 1947 Pap/1 A? Co/vz p MILL/7190 LEW/6 W ATTORNEY Patented Sept. 12, 1950 PILE FABRIC Ralph R. Gone and Willard Lewis, Augusta, Ga., assignors to Riverside Mills, Augusta, Ga., a. corporation of Georgia Application April 28, 1947, Serial No. 744,418

12 Claims.

Apart from the mechanization of the loom, there has been but little progress of a basic nature in the commercial production of rugs and carpeting over th many centuries during which the art has been practiced. For the most part, weaving has been resorted to entirely as the only acceptable method for producing such pile fabrics commercially.

There have been attempts in the past to fabricate pile fabrics by the use of adhesives, including latices of natural and synthetic rubber, but as far as is known prior to the present invention, no products of this type have proved to be satisfactory to the consuming public, nor has any method been developed to a point which has been considered as acceptable as a substitute for weaving.

Manufacturers have readily conceded that there must be a more rapid and less expensive method of producing fabrics of this type than the increasingly costly and time consuming operations involved in weaving, but despite the expenditure of vast amounts of time and research on the subject, they have been unsuccessful in producing an acceptable solution.

Many of the problems encountered and various steps towards their solution have been recounted in the patent to Ralph R. Cone, No. 2,344,537, dated March 21, 1944; and in applications filed in the name of Ralph R. Cone, Serial No. 575,232, filed January 30, 1945, now Patent No. 2,482,655, September 20, 1949; Serial No. 640,350, filed January 10, 1946, and Serial No. 662,837, filed April 17, 1946.

The products resulting from the methods and apparatus of these prior disclosures have proved to be eminently satisfactory as the pile elements employed for the production of the pile fabrics contemplated as well as the methods set forth in the present application.

The advantages of the fabrics produced in accordance with the present invention, from the standpoints of appearance, wearing qualities, costs and adaptability, are outstanding. Now that the extensive research required by this invention has overcome the many difliculties accounting for previous failures, the method has evolved as a, relatively simple one, requiring, a minimum of manual operation in its application.

The pile fabrics contemplated herein comprise a plurality of textile pile elements having base portions secured by an adhesive, to one another and/or to a backing. The free ends of the pile elements define a surface of the fabric, usually the finished surface. The fabric may comprise a plurality of layers of textile pile elements having base portions of adjacent layers secured together in compacted contacting relationship and/or to a backing, by an adhesive. Attachment of the pile elements to the backing is preferably accomplished solely by an adhesive of natural or synthetic latex which can be cured. The backing itself may be of textile material, which may be loosely woven to produce a relatively open mesh. spacer elements may be interposed between certain of the pile elements, within loops defined at their base portions and/or between adjacent layers of the elements, secured thereto by means of stitching or adhesively, or both. The free ends of the pile elements may be substantially coextensive and accordingly, substantially coplanar, although surface modifications of the product are also definitely contemplated.

The method contemplates the production of pile fabrics comprising arranging a plurality of layers of flattened helically formed self supporting textile bodies with their narrow edges substantially coplanar and adjacent layers in contacting relationship, adhesively securing the edges together, and severing the bodies in spaced relationship with respect to the edges. Inasmuch as a backing material will be employed for a large proportion of the products, the method contemplates securing the edges of the layers to such backing material adhesively. The various operations may be performed while the textile bodies ar advancing to render the method a continuous one. Since the arrangement of the textile bodies produces two surfaces defined by their narrow edges, backing material may be adhesively secured to both such surfaces while the bodies are advancing. This may be accomplished by adhesively applying a backing to one of the advancing surfaces defined by the narrow edges, curing the adhesive, exposing the other advancing surface defined bythe edges, adhesively applying a backing to this other surface, curing the second adhesive, and splitting the bodies intermediate the backings. Where the backing material is pervious, the adhesive may be applied either before or after the application of the backing material, to the edges and/or to the backing material itself, and the adhesive may be worked into the fibers of the material involved, as by a scrubbing action effected before or after the application of the backing to the textile bodies. Since in many cases, the textile bodies will be originally wound on their broad surfaces, provision has been made to unwind them and turn them through an angle of 90 through suitable arrangements of reeds, and feed them to a conveyor on which they will be compacted with their narrow edges defining an exposed surface to which the adhesive is applied. After the application of the adhesive, together with any backing material, the assembly maybe subjected to elevated temperatures for curing the adhesive, following which a similar series of operations may be appliedjo the opposite surface defined by the narrow edges of the textile bodies. v

A more complete understanding of the invention will follow from a detailed description of the illustrative embodiments depicted in the accompanying drawings wherein:

Fig. l is a fragmentary sectional elevation of one form of textile pile fabric contemplated;

Fig. 2 is an elevation as it would appear from the right end of Fi 1;

Figs. 3, and '7 are plan views of some of the textile elements or bodies suitable for use in practicing this invention;

Figs. 4, 6 and 8 are sectional elevations as they would appear from the right ends of Figs. 3, 5 and 7 respectively; and

Fig. 9 is a somewhat diagrammatic fragmentary perspective view depicting the sequence of operations illustrating one embodiment of the method contemplated by this invention.

The rug or other pile fabric 20 depicted in Figs. 1 and 2 comprises a plurality of layers of pile elements 22, each of which is defined by a filament or strand of textile material 24 having free ends 26 defining a surface of the fabric, and a looped base 28, to one side of which is secured by stitching 30, a spacer element 32. The textile bodies thus constituted, are assembled in compacted, contacting relationship to a backing 34 which may be a loosely woven material having warp threads 36 and weft threads 38. The textile bodiesor layers 22 are secured to the backing and to one another by means of an adhesive II which may be a cured latex of natural or synthetic rubber.

The textile body depicted in Figs. 3 and 4 may be produced in accordance with the disclosures of the Ralph R. Cone applications to which reference has been previously made, or otherwise. It is the form represented by these figures which has been employed by way of example for producing the fabrics depicted in Figs. 1 and 2. The textile filament or strand 24 having been arranged as a flattened helically formed self-supporting textile body with a spacer element 32 of textile or other suitable material secured near its base portions by stitching 30, provides relatively broad surfaces 42 and relatively narrow edges ll.

Another form of textile body or layer, selected by way of example from the applications previously referred to, has been depicted in Figs. 5 and 6 wherein the assembly of the spacer elements to the flattened helix is accomplished by means of an adhesive 46, in lieu of or in addition to stitching or sewing illustrated in the preceding figures.

Figs. '7 and 8 illustrate another example selected from the applications referred to, somewhat similar to Figs. 3 and 4, but including in addition, a spacer element 48 of textile'or similarly suitable material included within each loop formed by the filament or strand 2! at the narrowedges of the flattened helical body. These internal spacer elements 48 are secured in this case by stitching 30 which also serves the function described with reference to Figs. 3 and 4.

It should be emphasizedthat these examples of textile bodies which have been found to be satisfactory for the present purposes, are by no means exhaustive, since spacer elements may be omitted entirely or otherwise related, and produced in any convenient manner so long as they possess the characteristics essential to performing the method and producing the products contemplated herein.

Textile bodies such as those illustrated in Figs. 3 to 8 inclusive have been depicted in Fig. 9 as reeled upon cylinders arranged in four banks. The number of such textile bodies reeled upon each cylinder in edge to edge relationship will be governed by the dimensions in a transverse direction to be imparted to the completed fabric. The textile bodies 22 are passed through a reed 52 in adjacent stacks, each stack comprising a body from each of the four reels. From the reed 52, the stacks are fed between positively driven advancing rolls 54 and 56, rotated by means of gears 58 and 60 respectively through suitable shafting 62 suitably coupled with a line shaft 6| which is in turn driven through reduction gearing 66 by a source of power such as a motor 68. The driving speed may be varied by suitably controlling the motor and/or the reduction gearing, or in any other convenient manner known in the arts.

Beyond the rolls 5 and 56, the textile bodies are twisted through an angle of 90 and individually threaded through a reed 10 from which they pass to a conveyor 12, which may suitably assume the form of an endless belt as shown, driven through convenient mechanism coupled to the line shaft 64 through shafting 14. As the textile bodies advance to the conveyor, they are compacted to a desired degree of contact at their bases by means of vertical rails 16 which may be adjusted to assure the proper degree of compactness and contact as will eliminate undesirable spacing at the bases of the bodies or layers forming the finished fabric.

After the textile bodies have been assigned their proper relationship on the conveyor so that their upper edges are substantially coplanar, such edges pass under a roller 18 which deposits adhesive 80 from a fountain 82 over the entire surface thus defined. The nature of the adhesive is preferably such as would be provided by natural or synthetic rubber latex so as to produce a firm bond after suitable curing or drying.

The coating roller 18 is depicted as driven in opposition to the direction of the advancing textile bodies through a suitable mechanism comprising shafting 84 coupled with the line shaft 64. Following the application of the adhesive, the advancing textile bodies have applied over the adhesive, a backing material 34 which maybe a woven fabric, of textile or other suitable material, and which may have a relatively open mesh. The backing material is supplied from a reel 86 and applied to the surface defined by the textile bodies and their adhesive coating under a curved guide or shoe 88. Where the backing material is of relatively open mesh, the adhesive may be worked through it, as by means of brushes 9|! mounted for reciprocation transversely of the conveyor through suitable mecha-,

and to the backing, the relatively open mesh of I the latter having resulted in a coating of adhesive on its exposed surface. From the drier. the fabdo is delivered from the conveyor 12 to a tensioning roller I00 around which the fabric is threaded and given a predetermined desired tension by means of springs I02. From the tensioning roller, the fabric passes through an upper floor I04 and is fed with its backing lowermost on to a conveyor 12 similar to that previously described, where the now exposed relatively narrow edges of the textile bodies are coated, backed, worked, and cured or dried by a mechanism corresponding with that already described for similar functions, and correspondingly identified.

The fabric delivered from the upper drier 04 comprises the layers of textile bodies having backing material adhesively united to both of the surfaces defined by the narrow edges of the textile bodies and with the adhesive material suitably cured, rendering the fabrics ready for splitting in accordance with practice which is generally known in the art. The fabric is delivered from the upper conveyor I2 under a guide roller I06, then it is elevated to travel over a positioning roller I08 between a pair of horns H0, at the bight of which a traveling or band knife 2 is positioned to split or sever the textile bodies intermediatetheir backings. The upper portion of the pile fabric resulting from this splitting operation is advanced by engagement of a spiked or toothed member II4 engagin the backing under the pressure applied by an opposed cooperating roller H6, whereupon this portion of the pile fabric is wound upon a reel I I0 under the influence of a driving roller I frictionally engaging the backing, and flexibly related, in a manner not shown, to compensate for varying diameters in a manner well known in the art.

The lower portion of the fabric resulting from the splitting operation is likewise fed by a spiked or toothed member I22 engaged with its backing and cooperating with an opposed pressure roller I24, to a reel I26 on which it is wound by a roller I28 similar in function and operation to the roller I20 described in connection with the upper portion of the fabric. The mechanism for feeding and reeling the two severed portions may be driven by a motor I30 connected through a shaft I32 with suitable gearing I34, which may be of a variable type, which in turn drives a sprocket I36 secured to a shaft I38. The remote end of the shaft I38 will suitably drive the winding roller I28, while the sprocket I transmits motion through its chain I40 to an upper sprocket I42. The upper sprocket I42 is secured to a shaft I44 for driving the winding or reeling roller I20 for the upper portion of the fabric, which shaft also carries a sprocket I45 for driving a chain I48 received by another sprocket I50 for driving the shaft I52 carrying the spiked member II4. Synchronism between the shaft I52 and the shaft I54 of the lower spiked member I22 is maintained through suitable gearing I56.

The directions of movement of the various elements of the mechanism of Fig. 9 have been depicted by means of arrows to facilitate an understanding of the operations involved. The driving connections for the positively driven elements have been shown diagrammatically by broken lines, for the most part, to avoid obscuring the more important features, with the understanding that suitable mechanical movements of types well known in the art can be incorporated by any worker skilled in the art.

Whereas the examples of the products and method described herein are in themselves highly satisfactory, it will'be appreciated'by those skilled in the art, as it has been already recognized by' the inventors, that various departures from these examples may be effected with highly'desirable results. now that the basic problems have been solved. For example, the invention contemplates the production of pile fabrics utilizing various forms of textile pile elements, including any of those described in the Ralph R. Cone disclosures above referred to, withany number or arrangement of the spacer elements, appliedintemally and/or externally of the textile elements, by stitching and/or adhesively, or otherwise, or without such spacer elements. The fabric may be removed from the apparatus after application of a backing to only one surface, in which event, the exposed ends of the pile elements will assume the form of looped free ends, as distinguished from the severed free ends which result from the splitting operation. Accordingly, it is not intended that the invention be restricted to the examples illustrated and described beyond the scope of the appended claims.

We claim:

1. A pile fabric comprising a plurality of textile pile elements having base portions secured together by an adhesive and having free ends defining a finished surface of the fabric, and textile spacer elements secured between certain of said pile elements near' their base portions only.

2. A pile fabric comprising a backing. a plurality of textile pile elements having base portions secured to said backing solely by an adhesive and having free ends defining a finished surface of the fabric, and textile spacer elements secured between certain of said pile elements near their base portions only.

3. A pile fabric comprising a plurality of textile pile elements having base portions secured together by an adhesive and free ends defining a finished surface of the fabric, and textile spacer elements secured to certain of said pile elements near their base portions only.

4. A pile fabric comprising a plurality of textile pile elements having base portions secured together by an adhesive and free ends defining a finished surface of the fabric, and textile spacer elements sewed to certain of said pile elements near their base portions only.

5. A pile fabric comprising a plurality of textile pile elements having base portions secured together by an adhesive and free ends defining a finished surface of the fabric, and textile spacer elements adhesively adhered to certain of said pile elements near their base portions only.

6. A pile fabric comprising a plurality of textile pile elements having free ends and looped base portions, said base portions being secured together by an adhesive and said free ends defining a finished surface of the fabric, and textile spacer elements secured between certain of said pile elements near their base portions only.

'7. A pile fabric comprising a plurality of textile pile elements having base portions secured together by an adhesive and substantially coextensive free ends defining a finished surface of the fabric, and textile spacer elements secured to certain of said pile elements near their base portions only.

8. A pile fabric comprising a plurality of textile pile elements having base portions secured mam together by an adhesive and substantially coplanar free ends defining a finished surface of the fabric, and textile spacer elements secured between certain of said-pile elements near their base portions only. i

9. A pile fabric comprising a plurality of layers of textile pile elements having base portions of adjacent layers secured together in compacted contacting relationship by an adhesive, a textile spacer secured to the base portions of said elements constituting certain of said layers, and free ends of said elements defining a finished sur-. face of thefabric.

10. A pile'fabric comprising a backing, a plurality of layers of textile pile elements having base portions of adjacent layers secured in compacted contacting relationship to said backing by an adhesive, a flexible spacer extending normally to said elements and secured to certain of said elements near the base portions thereof, and free ends of said elements defining a surface of the fabric.

11. A pile fabric comprising a backing, a plurality of layer; )f textile pile elements having looped base portions, the base portions of adjacent layers being secured together in compacted contacting relatonship and to said backing by an adhesive, 9. flexible wacer embraced by said looped portions and secured thereto, and free ends of said elements defining a surface of the fabric.

12. A pile fabric comprising a plurality of layers of textile pile elements having spacer elements secured only to base portions thereof, said layers being secured together in compacted contacting relationship by an adhesive. and free ends of said elements defining a surface of the fabric.

. RALPH R. CONE.

WILLARD mswrs.

:REFEBENCES crrnn The following references are of record in the file of this patent:

UNITED STATES PATENTS 

